Apparatus for casting metal



'July 28, 1942. J. o. BETTERTON E-rAL 2,291,204'

APPARATUS FOR CASTINQ METAL Filed voct. 17. 19:58 :s sheets-smet 1l JUY'28-1S42Q J. o. BETTERTQN Erm.. l 2,291,204

APPARATUS FOR CASTING METAL Fild 06?.. 17, 1938 3 Sheets-Sheet 2- Patented July 28, 1942 APPARATUS FOR CASTING METAL Jesse 0. Betterton, Metuchen, and Frank F. Poland, Highland Park, N. J., assignors to American Smelting and Refining Company, New York, N. Y., a corporation ot New Jersey Application October 17, 1938, lSerial No. 235,431

12 Claims.

The J= -resent invention relates to a mechanism for facilitating the handling of indenitely long cast shapes of metal,.such as metal rod producedby continuous casting operations.

The production of metallic castings of indefinite length in a continuous manner is receiving a considerable amount of attention. In accordance with this process, molten metal is supplied from a reservoir or source thereof to one end of a die or mold having solid metal in the other end which serves as a plug and toWhich the molten metal welds as it solidiles, accompanied by withdrawal of the cast shape at a ratey substantially equal to that of solidication of the metal.

Upon observing proper precautionary measures in the process, the metal may be withdrawn from the mold or die in a continuous manner and for indenitely long periods of time without interruption to the casting process, the metal being withdrawn as a. continuous rod of indenlte length and of desired predetermined diameter, depending upon the inside diameter of vthe die. Furthermore, since the cast rod is produced in a continuous manner and without interruption to the casting operation, it becomes necessary to provide means for handling the production of the cast metal in an expeditious manner.

It has been mentioned above that upon observing proper precautionary measures in the process, the metal may be withdrawn from the mold or die in a continuous manner and for indenitely long periods of time without interruption to the casting process. These precautionary measures include certain factors in the manner of operation.

Among these factors there may be mentioned, specically the following:

1. 'I'he provision of means for preventing slipping of the rod during casting. In order to avoid The avoidance of slipping is of importance also in that the steady withdrawal of the rod is an .important consideration in maintaining a desired freezing zone in the die, for example in maintainsuch contingency, the said m'eans providefor a firm support against both lateral and longitudinal slippage, and accordingly it is preferred to provide a plurality of pointsof support for the rod in order to hold therod rigid. Accordingly,

' the withdrawal of the rod from the die is controlled by'providing preferably at least two sets of rollers which -diametrically oppositely engage the i rod, all of the rollers being power driven as further security against slippage of the rod. This is an important consideration especially in those instances where the rod being cast is of large diameter and it is necessary to sawit to make A billets of predetermined length, land where the rod must be cocl when it is sawed.

ing constant the casting conditions for the production of a copper casting with a definite radially crystalline structure.

2. The rollers should be adjustable as to tension, and means are provided. for this 'purpose so that the rollers are maintained against the rod with constant pressure, while enabling the rollers to yield responsively to' any variations in the .rod diameter so as to be self-accommodating relatively thereto.

3. The provision of means 4for cutting the rod without checking the movement of the rod as it issues from the die. `Such means may include coiling means for the rod and shearing mechanism, where the rod is a light rod, these means being positioned either adjacent to or remote from the casting furnace. When the rod is too inherently stiff for coiling, or Where straight lengths of rod are to be cut, the cutting mechanism, either a saw or shear. is mounted so as to move with the rod during cutting operations, so as not to check the casting nor bind the cutting means.

4. 'I'he rollers describedabovel are to be operated, at constant speed, which means that the source of driving power for the rollers is to be adapted to maintain a constant speed under variable load, and to increase the speed of the rollers by smooth increments on starting. u

5. The driving mechanism for the rollers should be enclosed in a suitable casing or housing for protection of the mechanism 'and to prevent contact of molten metal therewith in the event of run-outs or other accidental scattering of the metal being cast.

The above considerations indicate pal objects of the present invention, thewscope of which is intended to include any `mechanical means which will perform in accordance withthese indications and which will produce the results indicated by these considerations. Accord'- ingly, .the specific mechanical equipment employed or the specic arrangement of operating parts may be varied very widely, and the same which will be described herein are to be regarded only as illustrating one form of assembly which is suitable for producing these results.

Inadditionto the above, however, further ob- ,ects of the invention include the lprovision of means for enabling the withdrawing mechanism for the cast metall to be adjusted with respect the princivillllsfifhted -in Fig.

of A

i' Fig. 1, but in which the ooiling mech.

.anismis which may be easily controlled and operated.

with the minimum of labor.

with respect to these additional objects of .the

invention, it may be mentioned, particularly, that it is important to withdraw the casting straight out from the die.' I n the case where copper and/or copper alloys are belng cast, it has been y found that attainingy casting rates suiilciently high to produce commercial outputs of cast metal is accomplished by applying drastic cooling to the die walls so that heat from the metal being cast is Withdrawn very rapidly radially from the metal and through the walls of the die, so that the die is made with walls as thin as possible in order to conduct the heat rapidly from the molten metal to the water jacket enclosing the die, while withstanding the mechanical strains to which supply thereof in the reservoir becomes depleted.,

andthe reservoir is provided with a casting die or mold E enclosed in a divided water jacket F, the molten metal solidifying in the casting die, from .which the solidified metal is withdrawn lcontinuously as a'rod G of indeflnitelength. For

facilitating manipulation there is provided the.

system of mechanism of the present invention, which mechanism includes a coiling machine for coiling the -rod, which is indicated generally at H together with shearing mechanism J with driving instrumentalities K for the coiling mechanism H Y I:.lhis mechanism is to be regarded as being illustrative only, as the specific type of mechanism forms no part of the present invention except as v an element in a system of assembled cooperating the die is'subjected. The material composing the die being graphite of low porosity the thin walls of the die render the die rather fragile under torsional strains. 'An angularV withdrawal of cast metal from the die results in rapid destruction ofy the die through attrition of the thin walls thereof, and also tends tofracture the die because of j the thin die walls.

In the accompanying drawings, 4

Fig.' 1 is an elevation, largely diagrammaticin character, of an apparatus "system constructed in accordance with the present invention, showing diagrammatically in section the continuous casting unit. Y

Fig. 2 is an elevation of the coiling` mechanism of Fig. 1, the view being at right angles to Fig. 1

and taken on the line 2--2 of Fig. 1, looking in thedirection of the arows.

Fig. 3 is a plan view of the shearing mechanism the arrows.

Fig. 4 is detailed planz'view, partly in section, f lth shearing mechanisxxi'of Fig. 3.

Fig. 5 is a front elevation of the'mechanism of Fig-4, the vie'w being taken along the line i-l,

in the direction of the arrows.

,looking in the direction of the arrows. Fig. is a view of a control valve 'for controlling supply of' hydraulic, uid to. the' pressure linder of the shearing mechanism.

8 is adiagrammatic view of a piping system 'nimble for circulating hydraulic num sbearingmechanism. 9 is a diagrammatic 'elevation of an s spparatus somewhat similar to the eliminated andtheshearingm'echanlsm the of Fig. ihas been replaced bv other cutting means. illustrated by meansof a samtbeview slwwingfmher dessiner inserivmeans for adimting these rollers.`

- l a side elevation ofthe mechanism of Tig. i, the view being taken along the line 6-8 of Fig. 4

2, the view being taken on the line 3-2 of Fig. l. looking in the directiomof tions in load. The illustrated form, however, Aproven in practice seen from the drawings, these rollers may be arranged suitablyin pairs as indicated at 2l, 2l', 22, 22', which oppositely engage the rod G, the rollers being mounted -on suitable shafts 28, 2l', 2l and 2l'.

These rollers control the withdrawal of' the rod G from the die E, and direct the rod into a tubular guide Il, which guides the rod to the coiling instrumentalities, which includes three cooperating rollers l2, I4, It, the roller I2 engaging the rod oppositely to the rollers 84 .and I. for imparting a convolution of desired radius to the rod, as is indicated at 38. These rollers I2, N, Il, are also driven i'rom the driving mechanism K.

This driving rmechanism as being only illustrative in its character, and it may be replaced by other suitable types, producing a constant driving yspeed regardless of variahas to be verysatisfactory in the control which it effects in the casting heed of l the rod G, the actuation of the coiling meanswgith for the supporting rollers for the v the consequent interrelatlon between the casting speed and the rate of coiling, these obviously having to be synchronized properly for satisfactory operation. l n

As illustrated, however, the driving mechanism K for the coiling unit includes a motor 2li which operates a variable speed reducer 2 through a Y V-belt drive indicated at 2, speed reducer 2 operates a driving shaft 2 which is mounted in bearings 2l., 252, and carries a driving pinion 2N on the end of the shaft.

AThe driving pinion "2N meshes with a large gear 2 which in turn drives a shaft 2li, the gear 2li having also a hub 20| to whichis secured suitably a sprocket 202 for operating a second sprocket 2 on the shaft 2l' through meansof a chain drive 2l., the sprocket 2 being provided withahub 26| whichkeysthesprocketlto the shaft 2l'.

Power is transmitted from the shaft 2l! through suitable power-transmitting instrumen chain drive arrangement, for

istoberegardedaiso example, or'a system of gears in housingv 210 and also rollers 28, 28', 20, 20' are operatedby suitable means, such as gearing or the like, not shown, in housings 210, 212, from the shaft 28'.

This internal power-transmitting mechanism is not illustrated, since it may vary in its details as will be apparent, and it specifically is not a part of the present invention.

As the rod G passes through the guide 30, it enters between the rollers 32, 34, 36, and is bent into a spiral coil as designated at 40, the convolutions of which may be supported on a rack 42, carried on a suitable-stand-44. The rod G is bent continuously as it feeds through the coiling rollers; and by adjusting the distance be; tween the roller 32 and rollers 34 and 36, these may be adjusted correspondingly the radius of the convolutions 38 of the coil 40 so as to vlary the diametery of the coil.

As the rod is produced and coiled, it passes a shearing mechanism which is indicated at J, and which may be of the construction illustrated in Figs. 3 to 6 inclusive, this mechanism being adapted to shear the rod as it comes from the coiling unit, without interruption to the continuous casting of the rod.

This shearing mechanism includes supporting standards, such as are indicated at 46 and 48,` on which standards are mounted a fixed shear fra-me 50 which includes arms 52 and 54 which are xedly connected to studs 56 and 58 of an annular collar 60 of a hydraulic cylinder 62. The frame 50 has a guide opening 64 therein, into which the rod G is inserted as ,the rod first reaches the opening, and within the frame 50 there operates the shearing lever 66 this lever moving across the opening 64, upon actuation of instrumentalities to be described hereinafter.

The shear 66 is pivotally mounted at one end on a pivot pin 68 which extends through the frame 50, the other end of the shear forming a yoke 10, which is pivotally connected by a pin 12 to a piston rod 14 having a hollow piston head 16 operating in the hydraulic cylinder 62.A Fluid'pressure is supplied to the piston head 16 maintain continuous the feeding of the rod from the die.

Stiiening members |22, |24 may be provided for the arms 52, 54 of the shear frame 50, these members being Welded to the said arms for reinforcement purposes. The frame 50 is anchored to the supports 46, 48 by suitable anchor bolts or the like such as are illustrated, for instance at |26, |28.

The height of the shearing unit may be adjusted by providing set screws, |30, |32, release of which will release the anchor bolts |26, |28 in the respective supports.

In Fig. 9, there is shown diagrammatically a. modified form of apparatus in which certain details of structure are illustrated, by which the principal objects of the present invention may' be attained. Y y

The view (Fig. 9) shows in greater detail than` shown in-the preceding views, means iolmounting and driving the supporting rollers for the rod so as to enable the rollers to yieldably engage the rod with constant force, and also to enable the rollers to be centered accurately with respect to the die.

The rollers 20, 2| are shown in the View as being mounted in a yoke |34, the shafts 26, 26 passing throughbearing blocks |36, |36' in the housing H, which blocks are slidably mounted in the yoke responsively to pressure exerted by springs |38, |38' which are compressed between the blocks and the abutment |40, |40 of the set screws |42, |42', the position of which screws may be adjusted by turningthe heads |44, |44' by aA suitable wrench, or other tool. The shafts 26, 26 vare supported, of course, by at least two of these blocks and yokes with corresponding through iiexible hose lines 80, 82, the former being connected to the cylinder 62 in front of the piston head, while the latter is Vconnected thereto behind the piston head, the connections being indicated, respectively, at 84, 66,'1iowV of fluid through hose lines 80, 82 being controlled by the operation of a suitable valve in housing 92, which valve is operated by a lever 94 which is connected to the valve stem 96, as shown at 98, and which is fulcrumed at |00 to bracket |02 secured to rousingSZ. This valve, being of any suitable standard construction, is not shown in detail. Y

Hose lines E'. 82 are connected to the valve through connectors |06, |08, hydraulic pressure being supplied te the Valve through either of lines ers |I4, ||6 desirably are provided, which turn on their axes H8, |20 unser frictional engagement of the rod with the rollers, thus keeping receiving power-transmitting means as lwill be mentioned further hereinafter. l

The mounting of the rollers 22, 22 in yoke |48 is similar to the mounting of rollers 20, 20'

in bearing blocks |50, |50 which are adjustable under the pressure of springs |52, |52' which pressure may be adjusted by suitable adjustment of screw |54, |54 as described above.

The screws |42, |42', and |54, |54' afford means -for aligning 'the rollers 20, 20 and 22, 22 accurately with respect to the opening in the die. Also, the springs render the rollers selfaccommodating to varying diameters of the rodv for the rod as a safeguard against the rod slipping. As further precautions, the rollers may have their rod-engaging surfaces knurled,4 and `both rollers of each set are power driven in order to grip the rod more positively. This is necessary precaution where a heavy rod is being cast.

As has beenI indicated previously, the specific characterpof the drive is unimportant, but for purposes of illustration, shafts 28 and 28 may l eachbe provided with two sprockets, |56, |58 and |56, |58', respectively, idler and take-up sprockets |60 and |62 also being provided.

An endless chain drive |44 engages the idler sprockets I, |42, passes beneath sprocket Ill and over sprocket |58, thereby driving both rollers, additional endless chain drives |44 and -I passing around the sprockets |58' and |58' on Vshafts 28 and 2l', and around the sprockets |46, |46' on the shafts 24, 24', thereby driving both rollers 20, 20'.

In Fig. 9, the coiling and shearing mechanism previously described has been replaced by a sawing arrangement. The saw itself is designated at |10, and it is mounted so as to travel with the rodduring sawing operations.

This saw is driven by a motor |12, the

` saw and motor being mounted on a frame, |14. Power is transmitted from the motor |12 to the saw |10 through pulleys |15, |16, ,and driving belts |18, the saw |14 being mounted on the end of a shaft Illl enclosed in a sleeve |82. The frame 14 is supported on a supporting frame comprising a horizontal arrn |84 'and vertical withdrawn continuously from the furnace without interruption to the continuous movement of the cast metal from the casting furnace, the said mechanism comprising a fixedly mounted guide member for the continuously moving metal, and a shearing cutter operatively associated with the guide member for shearing the cast metal at selected intervals without interruption to the casting speed of the metal.

3. shearing mechanism for cutting meta comprising the combination with supporting means, of a rigidly mounted member on the supsupport |86 the latter being swivelly and slidably mounted on the post |44 so that the saw may be swung against the rod G for cutting the latter. The entire saw assembly is balanced by a counterweight Hl. The end of the horizontal arm |84 is provided with a, releasable clamp |02 which is adapted to clamp onto the rod above the saw so that the entire saw assembly is moved downwardly along the post |44 while the saw cuts the rod G to cut oi! a billet of desired length.

When the cutting operation is completed the saw assembly is lifted for the next operation by stopping the motor, releasing the clamp |82, swinging the saw out of augment with the path of the rod by swiveling the saw frame |14 around the post les and lifting the frame along the support III until the frame reaches its high position. It will be understood, also, of course, that the cutting speed of the saw is such that the billet is severed before the frame reaches its lowermost possible position, a forcible drop to such position after the billet is severed being prevented by the clamp |92 on the rod G and the counterweight ISI which also maintains the saw-frame level with no binding tendencyV on the saw. The column i is supported atboth l ends, as indicated at |44 and |44 so as to be maintained entirely rltid.

f in which the mold cavity is vertically disposed4 and from which the casting continuously-passes.

downwardly to the severing mechanism positioned below, a plurality of pairs of rolls en- 'gaging the casting at a plurality of verticallyspaced stations intermediate the mold and severing mechanism to provides multiplicity of points of support for the casting and maintain same in true vertical alignment withy the casting mold at all times,'and mechanism for positively driv- 'ing all of the rolls simultaneously at the same speed and at a constantspeed irrespective of load variations.

2. Apparatus for continuously casting metals comprising thecombination with a casting furnace of apparatus for continuously withdrawing cast metal'from the furnace at controlled casting speed and mechanism for cutting the cast metal into predetermined lengths as it'is .being 75 of power for the saw. and power transmitting port having a guide opening therethrough for enabling metal to be sheared to be passed through the said member, a shearing blade pivotally connected to the said member and adapted to act on the said metal to shear the same, as it passes through the said membenand actuating -mechanism for operating the shearing blade.

4. Apparatus for continuously casting metals comprising the combination with a casting furnace adapted to deliver continuously cast metal rcdof indefinite length,' of continuously operating pulling and supporting rollers for the rod arranged to provide a plurality of stations for supporting the rod to prevent slippins thereof, sawing means for cutting the rod into predetermined lengths as the rod passes downwardly from between the said rollers, clamping instrumentalities for, the rod adapted to clamp upon the rod upon engagement of the sawing means therewith to prevent transmission of vibrations therethrough to the casting means during sawing of the rod,l and a mount for the sawing means and the clamping instrumentalities adapted to move downwardly with the rod during sawing operations thereon .responsive to clamping engagement of the clamping instrumentalities with the rod, and counterbalancing means for,`

said mount.

5. Apparatus forA continuously casting metals comprising the combination with a casting furnace adapted to deliver continuously cast metal rod of indefinite length descending vertically therefrom, of continuously operating pulling and supporting rollers arranged to engage the ro'd at a plurality of stations to prevent slipping thereof, means for sawing the rod as the -rod passes from between the last of said rollers, mechanism for actuating the sawing means to saw the rod, instrumentalities for enabling the. sawing means to be moved horizontally between operative and inoperative positions'relative to the rod, vertically movable mounting means for the actuating 'mechanism and the sawing means, means substantially' counterbalancing the mounting means, and means for gripping the rod during sawing thereof to cause the said mounting means to move with the rod during sawing thereof while preventing transmission of sawing vibrations to the pulling rollers and casting furnace during sawing.

6. Apparatus for continuously casting metals comprising the combination with a casting furvnace adapted to deliver continuously cast metal rod of indefinite length downwardly therefrom, of continuously operating pulling and supporting rollers for the rod arranged to provide a plurality-of stations for supporting the rod to prevent slippins thereof, sawing mechanism for cuttingthe moving rod transvers'eiv into a plurality of predetermined lengths without interfering withthe continuous movement of the rod, the said sawing mechanism including a saw, a source ing yeldable responsively to any bindingof the.

saw to prevent transmission of destructive shocks to Ithe mechanism, .mounting means for the saw mechanism adapted to be held normally in an upper position while being movable downwardly responsively to movement of the rod, and means for interconnecting the rod andmounting means for transmitting movement of the rod to the mounting means.

7. A machine for cutting a downwardly moving bar of metal into predetermined lengths comprising, in combination, clamping means'for the bar, and sawing mechanism for cutting the bar, both clamping means and sawing mechanism being mounted on a common tool head, means for substantially counterbalancing the weight of the tool head' during downward movement thereof, said sawing mechanism including a saw, a highspeed motor for driving the saw, and power transmission means between the motor and saw, the said motor driving the'saw at sumciently highf speeds to prevent chattering of the saw.

8. A machine for cutting olf successive longitudinal sections from a length of stock moving continuously in a downward direction, said machine having',` in combination, a vertically movable tool head, a power actuated cutter thereon, means on said head for clamping the stock and head together during operation of said cutter on the stock, and means for substantially counterbalancing the weight of said head during downward movement thereof. v

9. A machine for cutting off successive longitudinal sections from a length of stock moving continuously in a downward direction, said machine having, in combination, a vertically movable tool head, a power actuated cutter thereon, means on said tool head for clamping the stock and headtogether during operation of said cutter v on the stock, and means for at least partiallyl counterbalancing the weight of said head during downward movement thereof. Q

10. A machine for cutting off successive longitudinal sections from a length of stock moving continuously in a downward direction, said machine having, in combination, a tool head guide for vertical movement adjacent and parallel toA the advancing stock and adapted to move downwardly therewith, a, power actuated cuttercarried by said head andmovable horizontally across the path of the stock' to cut oifthe leading end portion of the latter, means opposing downward gravitational movement of said head and overcoming the weight thereof to hold the head in an upper starting position, and means on said head for clamping the latter and said stock together for movement of the two in unison.

11. A machine for cutting off successive lon gitudinal sections from a length of stock moving continuously in a downward direction, said machine having, in combination, a vertically movable tool head, a power actuatedv cutter thereon, guide means for said toolhead, means on said head for clamping the stock and head together during operation of said cutter on the stock, and means exerting a lifting force on said head to facilitate raising the head following cutting off ing together the head and stock for movementv thereof in unison, 'and means' returning the head upwardly to starting position upon release of the clamping means.

` JESSE O. BETTERTON. FRANK F. POLAND. 

